Method of making trim panels



INVENTOR.

IIIUUI I, Il

OGL 30, 195l F. LYIJYNEN METHOD oF MAKING TRIM PANELs 3 Sheets-Sheet l Filed April 3, 1946 F. L YUYNEN METHOD OF' MAKING TRIM PANELS` oct. 3o; 1951` Filed April 5, 1946 5 Sheets-Sheet 2 r v No V I n.-- 1. mi. LW/W- -WWr/- www i nk s INVENTOR.

Oct. 30, 1951 F. LYlJYvNr-:N 2,573,466

METHOD OF' MAKING TRIM PANELS Filed April :5, 194e 5 sheetsheet s I N VEN TOR. Hed ggg/76x21 Patented Oct. 30, 1951 METHOD (,)FMAKING TRIM PANELS Fred Lyijynen, Detroit, Mich., assignor .to Briggs Mfg. Co., Detroit, Mich., a corporation of Michigan Application April 3, 1946, Serial No. 659,405

ll rIhis invention relates vto ornamental panels and to the manufacture thereof, suo-h panels heing particularly, although not exclusively, adapted for use as inner trim panels of various types of vehicle bodies, especially automobile lood-ies. @ne such panel, suitable 'for 'use -in trim-ming -t-he inside of an automobile door, may comprise two contrasting sections, i. e. an -upper upholstered section and a --lower kick-pad Aor kick-panel section which, although of ornamental or decora-tive character, is uri-upholstered.

An object of the invention is to provide an virnproved method and appara-tus Vfor making -an ornamental Vpanel of the type having a fa-lorie covered foundation and in which the fabric or trim covering Lmaterial is bonded to the foundation-'through the medium of -a thermoplastic or thermosetting resi-nous substance.

A Afurther object -of -the invention is to improve lthe manufacture of ornamental trim panels of the type hav-ing a foundation, atop layer Aor covering of fabric andan #interposed layer -of padding, important `feature -of the invention residing fin the -vprovision ofv improved inea-ns for stretching the lfabric over the padding and foundation layers and vthe bonding -of the layers While-'the fabric -is in stretched condi-tion.

.Another -obiect -of A`the invention is `to produce in improved lmanneiwa Vtrim panelorthe like having an upholstered section and an Jadjoining kickepanel section, Aprovision being made `for -consolidating together and .to -the foundation adjacent ledge lportici-1s of the cover sheets of the upholstered and kick-panel .sections and thereafter stretching the fabric coversheetbeforesecuring the oppositeedge thereof to the iounda' tion.

Still another -objec't of the invention is topro vide means for bonding and holding one ledge of the :fabric Acover sheet to the foundation lwhile lthe-.opposite edge is drawn over the edge of the .foundation to stretch the fabric, these latter edges being bonded together while the vfabric his instretched or :taut-condition.

A rfurther Iobject of ythe invention .is fto impress ornamental grooves .or depressions 5in-the `covering material of the trim vpanel .and to rbond this ymaterial to the-foundation vat the locality -of the grooves ondepressions, -said impressing opera tion being Iperformed -while the fabric covering of the panel is instretched orgtaut -condition.

Another object of the invention is to Jattach a plurality of fastener vdevices Ato fthe-underside of the foundation sheet during the Yfabrication of the A4trim panel, 4the Yfasteners -being united to .9 claims. (o1. d-,106)

2 the foundation through lthe medi-um of `resin pregnated materials which are Aconsolidated under heat and pressure vwith the foundation. Other objects of this invention will appear rhin the following description and appended claims, reference being had to -the accompanying drawings forming -a part o-f `this specification wherein like reference characters-designate corresponding parts inthe several views. Fig. 1 isa plan view of a tri-m panel constructe in accordance with the inventionvfthe-metalniold- -i-ng or ornamental finish strips being voi-nitted in this view. i

-Fig 2 -is a view similar lto Fig.- 1 'but illustrating the metal -nioldings installed onthetr-im panel. Fig. 3 is a sectional elevation of `a -die or mold apparatus taken longitudinally through substantially the middle of-the trimpanelto be formed, the dies in this wview being shown in 'open posi'- 'tion. v Fig. 4 is a `View similarfto Fig-3 but illustrati-ng the dies fully-nosed. Fig. 4A is an emarged sectional view illustrat -ing details 4enclosed within the dotted circle-4A of Fig. 4. Fig. 5 is an Ienlarged .detailed ysection of the parts enclosed wit-hin the circle-S- inFig 3.

Fig. 6 is an enlarged 'fragmentarysection of the fabric stretching mechanism with the dies in opened position. v Y

Fig. 7 is a view "milar-toFig. -6 but illustrating the dies in closedjposi-tion.

Fig. 8 is an enlarged fragmentary section taken through the dies substantially -alonglines `84-'8'3of Fig. 1 looking inthe direction ofthe arrows. V

Fig. 9 is an'en-larged section Atakenthroughthe dies substantially along lines-S-"S Vof Fig. '24100K- ing in therdir-ection the-arrows. f I A Fig '1'0 is 3111 emaled lamentay SQQQU taken through the dies substantially alongflinhes ln-lo ofvr'ig. a'lpqlging :in the directionfgf the arrows. n

Before explaining 'in .teni-1 ne .present invention it is Ato beunderstonodthat the invehtionis not ylimited in its application to the `details of construction and arrangement of parts illustrated in the accompanying drawings, since rthe invention is capable of other 'embodiments and of beingvpracticed pr carried putin various ways. Also it is to be understood that the phraseology or terminology employedfherein s'for the ^pimpose of description and not of limitation.

In Fig- '1 there is illustratedfgby werden@ plication of one embodiment fthe invention, an yornamental panel A adapted Vto be mounted astaae n the inside of an automobile door immediately below the window opening thereof for the purpose of covering the inner metal door panel and providing an ornamental nish for the inside of the door. The trim panel A is provided along the bottom thereof with an unupholstered so-called kick-pad or kick-panel section B which, in the present instance, is composed of consolidated laminations of sheet materials. The remainder of the trim panel above and laterally adjoining the kick-pad section B comprises an upholstered or fabric covered padded section C which, in the present instance, occupies the principal area of the panel and is formed on the fabric side thereof with ornamental grooves or depressions which may follow any desired design or pattern and in the localities of which the various laminations of the upholstered section of the panel are permanently bonded together. It will be understood that the design or pattern applied to the trim panel A and the'conguration thereof are shown in Fig. 1 solely for the purposes of illustration since they may vary widely in accordance with the requirements as to ornamentation and design.

The trim panel comprises a relatively heavy foundation board I covered in one area thereof with a layer of padding or wadding II which in turn is covered with a top sheet I2 or fabric or other equivalent trim material. The padding Il and fabric I2 form the upholstered section C of the trim panel. The adjoining area of the trim panel at the lower portion thereof, which is to -be formed into the kick-panel section B, is provided with a covering layer i3 which is preferably in the form of cellulosic material. The covering material I3 of the kick-panel section B is provided along its upper edge with an extended portion overlapped at I4 by an extended portion of the fabric I2, and as hereinafter described these overlapping portions of the sheets l2 and I3 are embossed or compressed by die operation and at the same time bonded or consolidated together. The fabric I2 along its upper edge has an extended portion I2a which, as shown in Fig. 3, extends beyond the upper edges of the foundation board I0 and padding layer Il.

The foundation board ID may be of any suitable composition, but is preferably formed of compressed fibrous stock so as to have the requisite strength, rigidity and stiffness. The foundation may be composed of one or a plurality of layers of paper of fibrous stock impregnated with a thermosetting resinous substance which are consolidated together under heat and pressure. The foundation may be treated or impregnated with a resinous substance and preformed to the shape illustrated, for example, in Fig. 3 with the resinous substance remaining after the preforming operation in an intermediate stage of reaction or polymerization. It will be understood that the foundation board i0 may be fabricated or prepared in various ways, such for example, as in the manner disclosed in co-pending application Serial No. 614,978 filed September '7, 1945, now abandoned.

In the preforming operation between heated dies the kick-panel section B is preferably partially formed or shaped so as to approximate the final shape of the kick-panel B in the completed article. Preferably the foundation material is impregnated with a resin, such as a phenol-formaldehyde or melamine resin converted into varnish by the use of suitable solvents. This resinous material is preferably only partially cured or reacted during the preforming operation, thereby facilitating the consolidation of the padding and covering. layers during the nal operations illustrated in Figs. 3 and 4. It will be understood that the covering material I3 for the kick-panel section may comprise one or a plurality of sheets, preferably thin alpha-cellulose sheets in the form of white wood pulp paper or other fine grain cellulosic material. The covering material I3 is preferably given an ornamental finish such, for example, as a wood grain nish which may be applied thereto in any conventional manner.

Afterithe preforming operation with respect to the foundation board I0, the latter is introduced into a press between upper and lower die members. The fabric material II and the covering material I3 are then superimposed in proper relation upon the foundation in the manner illustrated in Fig. 3 preparatory to the final operation of finally forming the panel to shape and consolidating together the various layers or laminations by the use of heat and pressure.

In the present instance the apparatus for completing the formation of the panel comprises a bed I5 upon which is secured a bottom die or platen I6. One edge of this platen at the upper face thereof adjacent the kick-panel is cut away to receive a die insert I1 rigidly secured to the platen I6. The upper surface of the die insert Il is shaped or contoured in accordance with the final shape of the kick-panel and adjoining portion of the foundation board I0. The opposite edge of the platen I6 at the upper face thereof is cut away transversely to provide a recess having a vertical wall I8 and a horizontal wall I9. Positioned within this recess in sliding contact with the wall I8 is a draw or pressure pad Z having a length corresponding to the width of the upper edge of the trim panel. This pad is recessed at 28a to receive the upper end of a compression spring 2 I, the lower end of this spring being seated within a recess 22 in the platen I6. Extended centrally through the coils of the spring 2l is a guide plunger 23 terminating at its lower end in a cylindrical head 23a having a sliding t within the cylindrical hole 24 in the platen. The plunger 23 has a threaded upper end screwed into a tapped hole in the pad 20.

The die or mold apparatus also includes an upper platen or punch member 25 recessed at one end to receive a stretching die insert 26 having a length corresponding to the length of the pad 28. This die insert projects somewhat below the adjacent lower face of the platen 25. Also anchored in fixed position within the recess in the platen 25 and lying adjacent the stretching die 26 is a creasing or embossing die insert 21, the lower edge of which terminates a predetermined distance above the lower edge of the die 26. Also fixed within the recess in the lower face of the platen 25 is a die plate or die insert 28 shaped or contoured to conform to the final shape of the upper surface of the trim panel. Fixed within a transverse groove or recess in the die insert 28 is a transverse grooving die insert 29. Also fixed within grooves or recesses in the die 28 are a number of longitudinal grooving die inserts 30, each being formed integrally with a narrow creasing or embossing projection 30a, see Fig. 8. A transverse die or pressure pad 3| is slidingly fitted Within a transverse opening 32 in the die 28, see Fig. 3. This die pad 3l is backed by a compression spring 33 extending intoa recess in the platen 25,

apte-,eee

thisdie pad being 'guided .by aheadedplimerl slidable within .a hole within the platen. yThe wor-king surface Pof the die`28 opposite the kiel: panel 'section B ofthe trim panel is curved or contoured 4to give the final fshap'e 'thereto fand termi'- nates in 'a projecting portion 35 (Figs. 3 and5) cooperable with the die insertlflito for-m .fan iin'-` turned edge along the 'lower edge fof 'the panel.

When the upper and lower die members `assume their relative positions sh'own in Fig- `x3., upon descent of the upper ram of the press'thepressre pad 3 Ilrst engages 'the panel iat the locality I4I of overlap of the fabric `|'2 and Tt'op Llalvr E'I3 of th kickepanel. As the -rain 'continues to descend from the position snow-i1 iniig. 3 tcwiramA the rpos'tion shown in Fig. 4 the stretching 'diefl engages the fabric extension 12a and clamps thisex# ten'sion against the upper Yface -offthe pressure pad 20. Continued descent of the liam lsults 1in drawing downward the fabric extension 2a @ver the edges of the foundation I0 and wadding II.

Since the fabric during this A, operation is clamped along the opposite edge thereof by the pressure pad V3l, the fabric witlfbefstretchedflongitudinally in the direction ofrthe, Yupper-edgeof the trim panel, thus rendering the fabric taut across the'facebfithe-panel fromilocalty I4 along the upper edge of the kiclrjpanel to the upper edge 'of the trim panel. vThe coaction of the stretching die 26 with thev pressure pad 2li will force the flatter downwardly toward thevpositi'on A of -Fig. x'7, and after sufficient stretching actionhas taken place on the fabric I2 the creasingor `embossing-die 2l will engage -thefabric I2 vand wadding `I'KI, compressing the sameand forming a de pressed groove 36 along theupper edge -of `the trim panel. Since the upper .platen and'associated die -inserts as Wella-as the lower 7platen AI6 are heated to the lproper temperature, thel action of V the-die insert 2'I in compressing the materials f to form the groove 36 will result in consolidating the fabric I2, wadding I I and foundation I0 along this groove and creating a permanent bond of these layers by completing the curing or polymerization of the resin with which the foundation and wadding is impregnated or treated.

After the stretching of the fabric has been completed the die insert 29 will engage the panel and compress the wadding and fabric to form a transverse groove or channel 3l therein. At the same time the ribs 30a of the die inserts 30 will form narrow vertical channels or grooves 38 in the fabric and wadding, and the pressure pad 3I will press together the kick-panel top sheet I3, fabric and wadding to form a transverse channel 39. In like manner ornamental grooves 43 may be formed in the upper face of the kick-panel (see Figs. 2 and 10) by means of suitable grooving die inserts.

Before the fabric I2 is applied to the padding Il preparatory to the die operation a suitable quantity of resinous material in the form of a lacquer is preferably applied, as by spraying or brushing, to the upper surface of the wadding in the areas 36, 37, 38 and 39. Hence, when the die members 21, 29, 3U and 3I engage the materials under pressure as shown in Fig. 4, the heat from these die members as well as from the die members I6 and l1 will consolidate together the various layers of the trim panel effecting a permanent bond therebetween and completing the polymerization of the resin.

After the trim panel has been removed from the die apparatus the free edgev of the fabric along the upper edge of the panel may be turned under andcementedY in [any @suitable manner pte the underside vof the foundation i0, as shown. in Fig. 9. Anornamentalmolding 4I may :be ,finsert'ed into 'the groove 'or channel 31 and secured mpositionlby suitable prong fasteners extending through holes 'in the Abottom ofthe 'channel and clinched over the bottom :of the foundation board. iin likermanner an ornamental `metal .molding strip :'42 maybe lodged `within the groove or channel 39 and V:secured viin .position .in the ysame manner 'as the molding 4I. `Similarly narrow ornamental `moldings '43 may Ibe anchored Within the .grooves "or channels '4.0 in the kick-panel section.

In thepresent embodiment .I 4have provided means for `attac'higng fa'sten'er `devices l"I4 to "the underside Vof the kick-panel -.section B `near the lower edge thereof,'the`se fasteners being .in tended for the fpurpose of attaching the 1lower edge lof the trim lpanelrto` 'the inner metal panel or frame of the door. -As shown in Fig. 5, each fastener .44, :which .is of the converging Lfprong type, has an upper terminal head 44a fccnned within -a .pad `or .piece of paper or fibrous .maf terial `45 Awhich has gbeen impregnated with a partially spolymerized resin. The pads 45, before assembling the. ytrim panel layers 'on the platen I6, lare lodged within recesses-146 lin the die Vinsert 11., as shown l'in Fig. 5. Asuitable number of. fasteners 44 Amounted iwithin pads -45are1provided and'spaced `apart vtransversely at the `desired locations. When the dies are clo-sedvthe heat and .pressure of .the cooperating dies will force the .pads 45 linto the yfoundation sheet -IU and consolidate them togethertocreatea permanent bond resulting from Vthe nal polymerization of 'the resin. rThus,it will v`beseen .that this operation will result in permanently installing the fasteners '45 'along .the lower edge .of the trim panel.

I claim:

1. The method of making a trim panel, including the steps of covering an area of a foundation material with a layer of padding material and a superimposed fabric sheet, applying heat and pressure to one edge of the fabric sheet to clamp and bond the same to the padding and foundation materials, thereafter drawing the opposite edge of the fabric sheet over the adjacent edge of the foundation material to stretch said sheet, and thereafter applying heat and pressure adjacent said last named edge to bond the fabric sheet to said foundation material.

2. The method of making a trim panel, including the steps of covering an area of a foundation material with a layer of padding material and a superimposed fabric sheet, consolidating one edge of the fabric sheet against the padding and foundation materials to bond the same together, thereafter drawing the opposite edge of the fabric sheet over the adjacent edge of the foundation material to stretch said sheet, and bonding said fabric sheet to said padding and foundation materials adjacent said last named edge.

3. The method of making a trim panel, includlng the steps of covering an area of a foundation material with a layer of padding material and asuperimposed fabric sheet, consolidating one edge of the fabric sheet against the padding and foundation materials to bond the same together, thereafter drawing the opposite edge of the fabric sheet over the adjacent edge of the foundation material to stretch said sheet, and thereafter bonding portions of the stretched fabric sheet to said padding and foundation materials.

4. The method of making a trim panel, including the steps of covering an area of a foundation material with a layer of padding material and a superimposed fabric sheet, applying heat and pressure to one edge of the fabric sheet to clamp and bond the same to the padding and foundation materials, thereafter. drawing the opposite edge of the fabric sheet over the adjacent edge of the foundation material to stretch said sheet, and securing said last named edge of the sheet to the foundation material.

5. The method of making a trim panel, including the steps of covering an area of a foundation material with a layer of padding material and a superimposed fabric sheet, clamping a portion of the fabric sheet to the foundation material, thereafter gripping other portions of the fabric sheet and drawing the latter taut over the foundation material, and applying heat and pressure to portions of the taut fabric sheet to bond the same to the foundation material.

6. In the method of making a panel, the steps of covering an area of a foundation material with a cover layer, clamping an edge of the cover layer to the foundation material, thereafter drawing the opposite edge of the cover layer over the adjacent edge of the foundation material to draw the cover layer taut, and bonding the opposite edges of the cover layer to the foundation material while the cover layer is taut.

'7. In the method of making a panel, the steps of covering an area of a foundation material with a cover layer, clamping portions of the cover layer to the foundation material, thereafter gripping other portions of the cover layer and drawing the latter taut over the foundation material, and bonding portions of the taut cover layer to the foundation material.

8. In. the method of making a panel, the steps of covering an area of a foundation material with a cover layer, applying heat and pressure tc `portions of the cover layer to clampy and bond the same to the foundation material, thereafter gripping other portions of the cover layer and drawing the latter taut over the foundation material, and applying heat and pressure to portions of said cover layer while the same is taut, to bond said last named portions to the foundation material.

9. In the method of making a panel, the steps of covering an area of a foundation material with acover layer, clamping an edge of the cover layer to the foundation material, thereafter drawing the opposite edge of the cover layer over the adjacent edge of the foundation material to draw the cover layer taut, and bonding portions of the cover layer to the foundation material While theV cover layer is taut.

FRED LYIJYNEN.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date 892,702 Wyman July 7, 1908 V1,1'13,426 Herman Feld 29, 1916 1,838,103 McNally Dec. 29, 1931 `1,856,694 Correvont May 3, 1932 1,954,130 Higgins Apr. 10, 1934 2,169,798 'Haberstump et a1. Aug. 15, 1939 2,235,690 Teague et al. Mar. 18, 1941 2,250,335 Trishman July 22, 1941 2,274,951 Davies Mar. 3, 1942 2,341,978 Cunnington Feb. 15, 1944 2,369,658 Burns Feb. 20, 1945 2,382,004 Curran Aug. 14, 1945 

